ControlIT AC 800PEC Control System

The modular controller for high-speed performance

Drives

Wind Turbine

Light Rail Propulsion

Large-scale power converters and drives must be reliable, fast and precise. That calls for a control system with outstanding performance, such as the AC 800PEC. But why should the same controller not cope with slow processes, too, such as cooling circuits, monitoring and balance of plant? The AC 800PEC does it all: when it comes to high-speed processes in an industrial environment with all related ancillary tasks, it is the ideal controller.

The AC 800PEC is ABBs high-end process control system, and belongs to the ControlIT product line. The AC 800PEC is the optimum solution for combining the high-speed control requirements of power electronics applications low-speed process control tasks usually carried out by separate PLC units.
High Power Converter

The AC 800PEC controller is configured and programmed using Control Builder M, ABBs well-established programming tool, and MATLAB/ Simulink with Real-Time Workshop.

Series Voltage Restorer

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Key benefits
The AC 800PEC is a modular high-speed control system. The modules are arranged according to the required I/O configuration and the process. The AC 800PEC I/O modules are connected via optional high-speed point-to-point connections. The AC 800PEC supports up to 36 bi-directional fiber-optic PowerLinks.
Fieldbus (AnyBus-S) Ethernet TCP/IP (Com 1/Com 2)

CEX Bus

RS-232/RS-422 (Com 3) Optical links

RS-232 Service Port (Com 4)

PowerLink Optical ModuleBus

Performance
The AC 800PEC excels with a very high processing speed. It provides Very fast analog and digital process I/Os with a typical cycle time of 25 s Fast closed-loop control and regular process logic implemented in one controller Low-speed I/Os with a typical cycle time of 10 ms Very fast analog/digital conversion and nominal/actual value comparison, directly on the peripheral I/O module. the Control Builder M programming tool and to the PECView service tool RS-232 / RS-422 serial ports for a local process panel and/or service terminal Up to two on-board AnyIO ports for ABB Communications Expansion bus (CEX) and AnyBus-S modules for all common fieldbus types Up to 36 terminals for optical PowerLinks and ABB S800 optical ModuleBus for costeffective, noise-immune connections to I/O systems and power converters.

Connectivity
The AC 800PEC features outstanding ability to communicate with other control devices: Two Ethernet ports for connection to a plant control network, other processor modules,

Modular configuration
The modular-design AC 800PEC comes with: Units mounted onto a DIN rail or equipped for direct wall mounting

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 Hardware and communication modules according to process needs Any combination of fast and slow I/Os, large and small topologies, installed locally and remotely.

IndustrialIT integration
The AC 800PEC is fully integrated into ABBs ControlIT software environment. IndustrialIT Enabled products from ABB will set the standard for productivity and profits in future power, automation and information solutions.

Hardware
AC 800PEC hardware is optimized for power electronics control: Optical connection between controller and process I/O Fast peripheral I/O devices for control and measurement Program and data stored in Flash memory, no battery backup needed Compatible with standard ABB S800 I/O devices Suitable for field installation.

Plant Network

Ethernet TCP/IP

OptimizeIT Enterprise Systems Portal Operator Consoles

OperateIT Process

Software
The AC 800PEC is programmed with: ABB Control Builder M programming environment based on the IEC 61131-3 standard Optimized fast application code development based on MATLAB/Simulink with Real Time Workshop.

Ethernet TCP/IP

OperateIT Server

Control Network
Ethernet TCP/IP

CEX Bus Extension

Process Panel
CEX RS-422

ControlIT AC 800M

FieldIT Fieldbus Solutions

Fieldbus

ControlIT AC 800PEC

EngineerIT ControlIT Host Terminal

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The AC 800PEC hardware

The AC 800PEC system incorporates equipment that meets the most challenging and also contradictory requirements in process control. It includes a wide range of I/O modules to cover all power electronics control requirements. The different I/O modules can be connected to the AC 800PEC controller to cover most automation requirements in: Process industry Power generation and distribution Transportation and traction. The modular, energy-efficient design of the AC 800PEC allows operation without forced cooling. The modules are mounted on standard DIN rails and can easily be installed in distributed processes. The number of directly connectable I/O systems is limited only by the maximum available fiber-optic links to the processor (36 bidirectional links). Depending on the required performance, single, multiple or redundant bidirectional links are used between modules. Each module comprises a mechanical carrier, a base module and a configurable set of submodules which provide the required I/O terminals or communication interfaces.

AC 800PEC Combi IO for fast signal exchange

S800 I/O modules for low speed signal exchange

AC 800PEC INT interface system for direct IGCT converter contol

requirements and the selected communication with the upper control. The AC 800PEC controller module contains the processor, the optical interfaces to the peripheral I/O, the fieldbus, and interfaces to the upper control: Base unit AC 800PEC BP (backplane with slots for mounting the processor, the power supply, and the optical and communication modules) Processor module AC 800PEC CPU mounted on the AC 800PEC BP. The CPU is a fully-featured 600 MHz RISC processor with a 64-bit IEEE Floating-Point-Unit (FPU). It is optimized for applications with very fast control cycles Two AnyIO interfaces, each consisting of an AnyBus-S slot an additional AnyIO extension slot for an AC 800PEC CEX interface or special applications Up to 6 AC 800PEC optical modules for fiber-optic links to various I/O modules.

AC 800PEC Controller PP D113

The controller comprises a low power circuit with high reliability. The hardware can be configured freely, depending on the process

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AC 800PEC PINT for the control of thyristor modules

Communication modules Communication with external systems (i.e. the upper control via fieldbus) is via CEX or AnyBus-S fieldbus interface module, or via Ethernet ports on the processor module.
AC 800PEC Measurement Interface PECMI for current and voltage measurements

The CEX interface provides optimum connectivity with the complete ABB AC 800 CEX program, such as: MB300 Profibus master Ethernet The supported AnyBus-S fieldbus types are: Profibus slave CANopen slave Lon Works slave Interbus slave Modbus slave etc.

AC 800PEC PEBB Interface board for direct IGBT converter control

Programs and data are stored in a robust solidstate 16 MB Flash memory, which is formatted as a file disk. Active programs are operating out of the cached 64 MB SDRAM.

AC 800PEC CPU Com 1

Ethernet 1

CPU (PowerPC 750FX)

Com 2
Ethernet 2

Com 4
RS-232

AnylO Slot 2

AC 800PEC CPU

Optical Modules Slots 4 ... 6

FPGA (programmable logic)

Backplane interface

Memory (64 MB SDRAM)

PCI 1

Backplane

Disk (16 MB Flash memory)

PCI 2

CEX Bus Module (AnylO Slot 1)

Optical Modules Slots 1 ... 3

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I/O modules
The combination of a huge variety of I/O modules is another specific advantage of the AC 800PEC. The AC 800PEC is an open system that provides standard interfaces even for modules with customized design and functionality. All internal communication between the controller and I/O modules is achieved entirely by means of optical links. There are no electric connections between the controller and any I/O device. AC 800PEC Measuring Interface PECMI UA D140 Alternatively: 1 Traction Module DA D143, providing 13 analog inputs with various predetermined characteristics 18 digital inputs allocated to specific monitoring tasks. In order to adapt to various voltage and current levels, the Combi IO can be combined with low voltage divider boards (up to 1000 Vrms) and CT/VT sub-boards.

AC 800PEC Combi IO UA D149 The Combi IO UA D149 is a universal, remote I/O device for high-speed applications, and is part of the AC 800PEC control system. It is mainly used for sensing actual values in fast closed-loop control and protection circuits. The Combi IO comprises the basic module UA D141, which can be equipped with stackable I/O boards such as: Up to 2 Mixed IO boards UA D142, each providing 16 fast digital inputs / 8 fast digital outputs 6 fast analog inputs 2 fast analog outputs.

The Measuring Interface PECMI provides a high-speed current- and voltage-measurement device which supplements the Combi IO module. Active scalable inputs for up to 4 current sensors (e.g. LEM) are provided Inputs for voltage divider boards and CT/VT sub-boards are available. In order to adapt to various voltage and current levels, the PECMI can be combined with voltage divider boards: Voltages up to 1000 Vrms require a Low Voltage Divider (LVD) Higher voltages up to 6000 Vrms require the High Voltage Divider (HVD).

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AC 800PEC PEBB Interface Boards GD D160 and GD D165 The PEBB Interface Board is a universal remote I/O device for the direct drive of two IGBT converters with up to 2 x 6 pulses within ABBs Power Electronic Building Block (PEBB). It also measures and monitors all analog and digital signals from the two IGBT converters. Six additional parallel IGBT converters can be driven via extension interfaces. A measuring interface PECMI can be connected for current and voltage sensing devices. The PEBB Interface Quad GD D165 can be used as an alternative universal remote I/O device to drive up to four IGBT bridges with up to 4 x 6 pulses within a Power Electronic Building Block (PEBB).

Standard ABB S800 I/O System For slow process signals, the standard ABB S800 I/Os provides a large and flexible interface with a virtually unlimited number of analog and digital I/Os.

AC 800PEC INT Interface System PV D164 The PEC INT board comprises up to six optical modules with 6 transmitter/receiver channels to interface with the AC 800PEC control system and various converter types, e.g. for direct-firing pulse transmission to IGCT converters. The complete pulse logic is implemented in a programmable logic (FPGA) on the PEC INT board.

AC 800PEC PINT Pulse Interface DD C779 The board is used to control two independent 6-pulse thyristor converter bridges.

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Communication Process

> 1ms

IT environment Industrial 131-3 control software IE C 61

Slow p

Level 1 Typical cycle time

Simulink I/O Uniit

The key AC 800PEC capability is high-speed control application processing, as required in power electronics, for integration into ABB's standard ControlIT environment. Implementation of the AC 800PEC software on three performance levels provides a superb range of control and communication functionality:

100 s - 1 ms

Level 2
DPRAM

DL program plication VH Very fast ap timing sk ta tors st fa and modula re pulse logic to I/O hardwa n powerLink tio ec ot very fast pr

> 25ns

DPRAM

Simulink I/O Uniit

Software

B/Simulink tion MATLA Fast applica ps loo l ro nt co hine state mac protection

Fast p

Level 3

Level 1: IndustrialIT integration

This level is based on the industry standard IEC 61131-3 and contains the slow-control, monitoring, operating, displaying and registering functions. The development of programs in accordance with the IEC 61131-3 standard is carried out in the Control Builder M, ABBs IndustrialIT compatible engineering tool.

modulators, pulse logic with associated protective functions, fast analog and binary inputs and outputs, etc. It is implemented in the FPGA (Field Programmable Gate Array) and programmed in VHDL (Very High Speed Integrated Circuit Hardware Description Language).

Level 2: Fast control software

This level contains the fast control and protective functions with cycle times from less than 100 s to a few milliseconds. Fast, time-critical control and I/O tasks are programmed by means of MATLAB/Simulink and integrated into the ControlIT environment as a Simulink I/O unit. This allows perfect interaction between the high-speed AC 800PEC core functions and the standard ControlIT software.

Engineering workflow
The project-specific high-speed control tasks and configuration of the AC 800PEC-specific fast I/O are programmed by means of
Software developer Application engineer
Requirements specification Fast control application programming (MATLAB/Simulink, FPGA)

Level 3: High-speed I/O control

This level contains highly time-critical, hardware-specific functions such as pulse-width

Installation package (fast control appl. firmware)

Fast control application specification

Control IT application programming (Control Builder M)

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process I/O

Configuration access with Control Builder

Tools
ABB IndustrialIT provides a complete suite of AC 800PEC engineering tools for all phases of your automation project from engineering, installation and commissioning to operation and maintenance. The ControlIT environment programming and service tools are connected directly to the controller via Ethernet and RS-232 serial links.
OperateIT Process Panel Builder

process I/O

MATLAB/ Simulink and the Real Time Workshop (RTW). This requires special skills that can be acquired by suitable training. Alternatively, this part of a project can be assigned to ABB specialists, provided that all tasks are specified at the beginning of the engineering phase. The resulting program code is then downloaded to the controller by the application engineer using an Installer Package. The corresponding I/O specification is imported into the Control Builder M by means of standard commands. The application engineer only needs to access the ControlIT level to define the standard ControlIT tasks and interfaces (i.e. fieldbus and S800 modules). Applications are created using Control Builder M, and are then downloaded to the controllers.

ControlIT Control Builder

I/O specification

MATLAB/Simulink

PECView

ControlIT Control Builder M

The AC 800PEC software is managed with Control Builder M Professional, ABBs
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Windows 2000 integrated, IEC 61131-3 compliant engineering tool. A special add-on includes AC 800PEC-specific functionality. The AC 800PEC add-on provides full integration of the AC 800PEC into the ControlIT engineering environment. The license for the add-on is issued with the AC 800PEC hardware.

PECView
The PECView is a PC-based commissioning and service tool. It provides a complete set of features for analyzing, monitoring and maintaining Simulink applications running on an AC 800PEC system.

OperateIT Process Panel Builder

3BHS201058 ZAB E01 / 04.2004 Copyright 2004 ABB. All rights reserved.

The Process Panel Builder is the standard engineering tool for ABBs Process Panel product line. It provides a wide choice of operator panels for all requirements that can be integrated easily into an AC 800PEC control system, such as: Easy customization of operator graphics using a comprehensive library Standardized faceplate concept to minimize configuration time.

ABB Switzerland Ltd

Power Electronics Systems, Turgi CH-5300 Turgi / Switzerland Tel: +41 58 589 38 09 Fax: +41 58 589 20 90 E-mail: pes@ch.abb.com www.abb.com/powerelectronics

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Dokman AG